Section 5 Maintenance - Nordsonemanuals.nordson.com/adhesives/english_manuals/main_abc.pdf · 2004...

Maintenance 5-1

P/N 7105491A_1� 2004 Nordson Corporation VersaBlue_NW_PLC_AB

Section 5Maintenance

WARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

NOTE: Maintenance is an important preventive measure for maintainingoperating safety and extending the lifetime of the unit. It should not be ne-glected under any circumstances.

Risk of BurnsWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

Some maintenance work can only be done when the melter is heated up.

Relieving PressureWARNING: System and material pressurized. Relieve system of pressurebefore disconnecting hoses, guns and hot melt handguns. Failure to ob-serve can result in serious burns.

Relieve pressure as described in section Installation, Connecting Hose,Disconnecting.

Important when Using Cleaning Agents� Use only a cleaning agent recommended by the hot melt material

manufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

� Properly dispose of cleaning agent according to local regulations.

Maintenance5-2

P/N 7105491A_1 � 2004 Nordson CorporationVersaBlue_NW_PLC_AB

Processing Materials

Designation Order number Use

High temperature grease To be applied to O-rings andthreads

� Can 10 g P/N 394 769threads

NOTE: The grease may not be� Tube 250 g P/N 783 959

g ymixed with other lubricants.Oily/greasy parts must be cleaned

� Cartridge 400 g P/N 402 238Oily/greasy arts must be cleanedbefore application.

Sealing paste Stucarit 203: Applied to sealing surfaces

� Tube 100 ml P/N 255 369

Temperature-resistantadhesive Loctite 640

Secures screw connections

� 50 ml P/N 290 359

Heat transfer compoundNTE303

To improve heat conducting oftemperature sensors

� 1 g P/N 1023441

Preventive MaintenanceThe maintenance intervals are general guidelines based on experience.Depending on the operating environment, production conditions and melterhours of operation, other scheduled maintenance tasks may provenecessary.

NOTE: Coupling and motor controller are maintenance-free.

Melter part Activity Interval Refer to

Complete melter External cleaning Daily 5-4

Inspect for externaldamage

Daily 5-5

Purge melter withcleaning agent

When material is changed 5-6

Displays and lamps Safety and function tests Daily 5-5

Tank Clean tank by hand When there is material residue intank

5-6

Tighten fixing screws Every 500 hours of operation 5-6

Safety valve Activate piston Monthly 5-6

ControlLogix control unit:Processor board

Replace buffer battery Every 3 years

At the latest when the BATTstatus display is illuminated.

5-8

Fan and

Air filter

Check filter, clean orreplace if necessary

Clean fan screen

Depending on dustaccumulation; daily if necessary

5-8

Maintenance 5-3



Heat exchanger, (option) Clean

Performance check

Depending on dustaccumulation; daily if necessary

Daily

5-9

Power cable Inspect for damage Every time the melter is serviced –

Air hoses Inspect for damage Every time the melter is serviced –

Gear pump Tighten the gland bolt After initial startup 5-10

Check for leakage,tighten gland bolt ifnecessary

Dependent on hours ofoperation, pump speed andpump temperature

Recommendation: Monthly

5-10

Tighten fixing screws Every 500 hours of operation 5-10

Motor / gear box Change lubricant Every 15000 hours of operationor every 2 to 3 years

5-11

Clean fan cover Depending on dustaccumulation; daily if necessary

–

Pressure control valve Replace outer O-rings(service kit)

At the latest when leakageoccurs

5-12

Disassemble and clean Every six months Section SpareParts

Filter cartridge Replace filter cartridge

Disassemble and cleanfilter cartridge

Depending on degree of materialpollution

Recommendation: Every 1000hours of operation

5-15

Safety valve plate Replace O-rings (servicekit)

When pump is detached, at thelatest when leakage occurs

5-17

Tank isolation valve Replace O-ring (servicekit)

When pump is detached, at thelatest when leakage occurs

5-18

Pneumatic pressurecontrol valve

Performance check;clean or replace ifnecessary

Every six months 5-19

Pressure sensor Calibrate Once/year, more often whenconditions dictate

SectionOperation

Check separatingmembrane for damage

Every time pressure sensor isremoved, more frequently ifnecessary

–

Check whetherhardened or charredmaterial is stuck to themembrane; cleanseparating membrane ifnecessary

Every time pressure sensor isremoved, more frequently ifnecessary

5-20

Filling valve (option) Check control moduledetection hole; replacecomplete control moduleif necessary

When excess material seeps outof detection hole

(seals in inside worn)

5-21

Maintenance5-4


Preventive Maintenance (contd.)


Level and overflowprotection evaluators

Calibrate Only when evaluator or levelsensor is replaced

Section Repair

External CleaningExternal cleaning prevents impurities created during production fromcausing the melter to malfunction.

CAUTION: Observe the unit’s Degree of Protection when cleaning (Referto section Technical Data).

CAUTION: Do not damage or remove safety labels. Damaged or removedsafety labels must be replaced by new ones.

Remove material residue only with a cleaning agent recommended by thematerial supplier. Heat with an air heater if necessary.

Remove dust, flakes etc. with a vacuum cleaner or a soft cloth.

Nordson recommends the orange cleaning agent P/N 771 192 (12 spraybottles, 0.5 liter each).

Control PanelCAUTION: Switch off the unit before cleaning the control panel. This en-sures that no functions are unintentionally triggered by touching the screen.

NOTE: Nordson recommends placing a clear foil over the control panel;this will make cleaning easier.

CAUTION: Abrasive cleaning agents or solvents can damage the controlpanel. Do not scratch the control panel or use cleaning brushes.

1. Use a soft sponge or cloth and mild soap to clean the control panel.

2. Dry the control panel e.g. with a chamois to prevent water spots.

Removing Paint Splatters and GreasePaint splatters and grease can be removed with a 70 % isopropanolsolution. Clean with a mild soap and rinse with clear water.

Maintenance 5-5


Visual Inspection for External DamageWARNING: When damaged parts pose a risk to the operational safety ofthe melter and/or safety of personnel, switch off the melter and have thedamaged parts replaced by qualified personnel. Use only original Nordsonspare parts.

Safety and Function Tests

During power up of the melter, the lights in the light tower are all switchedon briefly as a test. The operator should check whether all lights functionproperly. Replace defective lamps.

Detaching Protective PanelsOpen the protective panels with a 4 mm Allan key.

On the inside

Fig. 5-1

Detaching Insulation Blanket1. Release Velcro and clamps.

2. Take insulation blanket out of hooks.

2

1

2

1

Fig. 5-2

X

Maintenance5-6


Changing Type of MaterialRemove old material from the melter (Refer to Tank, Draining Material).

NOTE: Before changing the type of material, determine whether the oldand new material may be mixed.

� May be mixed: Remaining old material can be flushed out using the newmaterial.

� May not be mixed: Thoroughly purge the unit with a cleaning agent rec-ommended by the material supplier.

NOTE: Properly dispose of the old material according to local regulations.

Purging with Cleaning AgentCAUTION: Use only a cleaning agent recommended by the hot melt mate-rial manufacturer. Observe the Material Safety Data Sheet for the cleaningagent.

Cleaning agent residue can be flushed out of the unit with new materialbefore production begins again.

NOTE: Properly dispose of cleaning agent according to local regulations.

Safety ValveActivate the safety valve piston once a month. This prevents the materialfrom blocking the safety valve.

Procedure:

1. Relieve melter of pressure as described in section Installation.

2. Disconnect all hoses.

3. Close hose connections with Nordson port plugs.

4. Mechanical pressure control valves: Measure insertion depth (Fig. 5-3: dimension X) of setting screw and make a note. This ensuresthat insertion depth can be reproduced. Then close pressure controlvalve.

Pneumatic pressure control valves : Set the compressed air supply to6 bar.

5. Operate the melter at full motor speed and with hose connectionsclosed. Switch the motor on and off several times.

Fig. 5-3

MXTK007S050A0495

Maintenance 5-7


Tank

Draining MaterialAllow the melter pump(s) to run until the material has drained from themelter.

CAUTION: Do not feed charred material through the gun. Particles canblock the gun. Instead unscrew the hose and feed the material out throughthe hose connection (Refer to section Installation).

If the Unit is Equipped with a Drain Valve (Option)

1. Place a container under the drain valve and open the ball valve.

2. Feed the material out of the drain valve and collect it.

3. Close the ball valve and dispose of the material properly according tolocal regulations.

Cleaning Tank by Hand

Cold material can usually be peeled off of the sides of the tank (Refer to Fig. 5-4). If necessary, first heat tank to material softening temperature,usually approx. 70 �C / 158 �F.

NOTE: The inside of the tank is release coated. Do not use metallic tools toclean. Do not use wire brushes! This could damage the release coating.

Fig. 5-4

Tightening Fixing Screws

Heating and cooling that occurs during daily operation can cause the fixingscrews to loosen. Tighten screw as indicated in the table.

NOTE: Tighten fixing screws only using a torque wrench and when themelter is cold.

Fig. 5-5

Connection Thread Torque

Tank / melter chassis M 8 25 Nm / 220 lbin

Grid (low melt) / reservoir (high melt) M 8 20 Nm / 177 lbin

Maintenance5-8


Replacing Buffer BatteryNOTE: To prevent loss of the program when the buffer battery is removed,the processor must remain on.

The battery must be replaced every 3 years or when the BATT statusdisplay on the processor lights up. Battery type 1756–BA1.

WARNING: Risk of electrical shock. Failure to observe may result inpersonal injury, death, or equipment damage.

NOTE: Make a note of the date of battery replacement on the batterycover.

Dispose of old battery properly according to local regulations.

Fan and Air FilterDepending on dust accumulation, the filters (1, 3) for the air inlet and outlet(4) must be cleaned (knocked out) or replaced.

Refer to section Spare Parts for filter order number.

1

2

3

4

Fig. 5-6

1 Air filter, top air inlet2 Fan

3 Air filter, bottom air inlet 4 Air filter, air outlet

Maintenance 5-9


Heat ExchangerThe melter can also be equipped with a heat exchanger. The frequency ofcleaning is a factor of the actual situation (dust and dirt accumulation).

1

2

3

Fig. 5-7

1 Air filter, top air inlet 2 Air filter, bottom air inlet 3 Heat exchanger

1. Release the four screws.

2. Remove the cover.

3. Clean the heat exchanger blades:

a. Blow out dust.

b. Rinse out grease and oil residue with soapy water (max. 75 �C / 167 �F).

NOTE: Dry well.

4. Put cover back into place and screw on.

Performance CheckNOTE: The heat exchanger can cool the electrical cabinet properly onlywhen the fans work. Two simple ways to check the performance of the fansare:

� Listen to whether the fans are operating

� Feel whether air is flowing out of the electrical cabinet.Fig. 5-8

Defective heat exchangers must be replaced.

Maintenance5-10


Gear Pump

Checking for Leakage

The gear pump is equipped with a self-sealing pump shaft seal. Materialmay seep out of the seal at irregular intervals. The gland bolt must then betightened.

NOTE: When the pump shaft seal needs to be replaced, Nordsonrecommends replacing the pump and sending the old one in to be repaired.Only trained personnel can replace the pump shaft seal.

Tightening Gland Bolt

NOTE: Tighten only when the melter and the pump are warm.

Tighten the gland bolt approx. � of a revolution in the operating direction ofthe pump. If tightening is no longer possible, the gear pump must bereplaced.

Fig. 5-9

Tightening Fixing Screws

Normal heat cycling (heating and cooling) can cause the fixing screws tobecome loose.

NOTE: Tighten the fixing screws only when the melter and the pump arecold. Tighten only with a torque wrench (25 Nm / 220 Ibin).

Maintenance 5-11


Motor / Gear BoxWARNING: Before beginning work near the motor, switch off the melter or,when present, switch off the motor circuit switch (motor maintenance switch,option).

The only motor maintenance required is cleaning the fan cap.

Changing LubricantNOTE: Use only the stated lubricant or one that has proven to be equiva-lent (Refer to Lubricant Selection). Using any other lubricant can result inpremature wear and/or damage to the gear box.

NOTE: Drain lubricant only when the melter is warm and the lubricant fluid.

Remove gear box from the motor to change lubricant. Wash out casing withsuitable cleaning agent and remove lubricant residue.

NOTE: Properly dispose of the old lubricant according to local regulations.

Lubricant Changing Interval

Operating temperature < 100 �C / 212 �F:Every 15000 hours of operation or at least every 2 to 3 years.

Capacity

The lubricant quantity is indicated on the ID plate. Ensure that the uppergears and rolling bearings are properly lubricated.

NOTE: Different types of lubricant may not be mixed.

Maintenance5-12


Motor / Gear Box (contd.)

Lubricant Selection

Lubricant manufacturer Lubricant (Mineral oil CLP 220)

AGIP Blasia 220

ARAL Degol BMB 220 or Degol BG 220

BP Energol GR-XP 220

DEA Falcon CLP 220

ESSO Spartan EP 220 or GP 220

KLÜBER Klüberoil GEM 1-220

OPTIMOL Optigear 220

SHELL Omala Oil 220

TEXACO Geartex EP-A SAE 85 W-90

Pressure Control ValveWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

WARNING: System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

NOTE: Screw in/out only when valve is warm and material is soft (approx. 70 �C / 158 �F, depending on material).

Maintenance 5-13


Installing Service Kit

Each kit contains two O-rings and high-temperature grease.

Fig. 5-10

Mechanical pressure control valve Pneumatic pressure control valve (option)

Service kit P/Ns: 394600 Service kit P/Ns: 394602

Required tools:Open-jawed wrench, size 24PliersTorque wrench

Required tools:Open-jawed wrench, size 27PliersTorque wrench

1. Heat melter to operating temperature.

WARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

2. Relieve melter pressure.

– 3. Close compressed air supply.

4. Refer to Measuring InsertionDepth

4. Unscrew air hose.

5. Use an open-jawed wrench to screw out the pressure control valve, thenextract with a pliers.

6. Remove old O-rings and disassemble and clean pressure control valve.Refer to section Spare Parts for detailed drawing.

NOTE: Disassemble valve only when warm.

7. Install new O-rings. Apply grease to all threads and O-rings.

8. Guide pressure control valve into the hole when the melter is warm andtighten with torque wrench.

Starting torque: 15 Nm (133 lbin)

9. Refer to Adjusting Setting Screw 9. Attach air hose.

– 10. Open compressed air supplyagain.

X

+–

Maintenance5-14


Pressure Control Valve (contd.)

Important for Mechanical Pressure Control Valve

Measuring Insertion Depth

Measure and make a note of the insertion depth of the setting screw(dimension X). This way the insertion depth can be replicated afterreassembly.

Fig. 5-11

Adjusting Setting Screw

Adjust the setting screw to the recorded dimension X.

� Turning clockwise increases material pressure.

� Turning counterclockwise decreases material pressure.

Fig. 5-12

1

2

Maintenance 5-15


Filter Cartridge

Replacing Filter CartridgeWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

WARNING: System and material pressurized. Relieve system pressure.Failure to observe can result in serious burns.

Removing Filter CartridgeNOTE: Remove the filter cartridge when the melter is hot and not underpressure.

M10

Size 24

Fig. 5-13

Installing Filter CartridgeNOTE: Install the filter cartridge only when the melter is hot.

1. Apply high temperature grease to all threads and O-rings (Refer to Pro-cessing Materials in this section).

2. Insert the filter cartridge (2, Fig. 5-14) in the filter bore and tighten some-what (approx. 1 Nm / 8.85 lbin).

3. Operate the pump and feed material.

4. Unscrew the deaeration valve (1, Fig. 5-14) until material flows out.Feed material until it comes out free of bubbles. Then screw the deaera-tion valve in again.

5. Properly dispose of material according to local regulations.

Fig. 5-14

Maintenance5-16


Filter Cartridge (contd.)

Installing Service KitEach kit contains three O-rings, filter sheath, filter screen andhigh-temperature grease.

Fig. 5-15

Service Kit, for P/N refer to section Parts List

Required tools:Open-jawed wrench, size 24 and size 13

2Size 24

1. Disassemble the hot filter cartridge (material must be fluid).

2

1

2. Replace filter sheath (1), O-rings (2) and filter screen (3).

3

13. Clean all other parts.

2Size 13

4. Apply grease to all threads and O-rings.

Maintenance 5-17


Safety Valve Plate


Each kit contains two O-rings, sealing paste and high-temperature grease.

Fig. 5-16

Service kit, for P/N refer to section Parts List

Required tools:Allan key, size 6



2. Empty tank.

3. Detach pump (Refer to section Repair.

4. Release the four fixing screws M8 from the safety valve plate and removeplate.

5. Remove old O-rings and when present, the filter screen in the suctionhole.

6. Clean sealing surfaces on tank, safety valve plate and pump.

7. If there is one, clean filter screen and place in the groove again, or replacewith a new filter screen (P/N 394072).

8. Apply high temperature grease to O-rings and sealing paste to sealingsurfaces. Attach O-rings.

9. Screw on safety valve plate.

10. Attach pump (Refer to section Repair).

11. Fill the tank.

Maintenance5-18


Tank Isolation Valve


Each kit contains one O-ring and high-temperature grease.

Fig. 5-17

Service kit, for P/N refer to section Parts List

Required tools:

Allan key, size 4PliersOpen-jawed wrench, size 13, to operate the tank isolation valve



2. Empty tank.

3. Release four Allan screws M5 and lift off plate. Use a pliers to extract thetank isolation valve from the safety valve plate.

4. Remove old O-ring and clean tank isolation valve.

5. Apply high temperature grease to O-ring, then install again with tankisolation valve.

Size 13

1

00: Closed

Tank side

Pump side

1: Open

NOTE: Operate the tank isolation valve only when the melter has reachedoperating temperature.

ÂÂÂÂ

ÂÂÂÂ

Maintenance 5-19


Pneumatic Safety ValveThe safety valves, preset at the factory and lead sealed, prevent higherpressurization than permitted of the subsequent pneumatic components.When the factory settings are exceeded, compressed air audibly escapes.

NOTE: The safety valves for the pneumatic options are located in themelter tower.

Performance Check

The performance of the safety valve should be checked approx. every sixmonths. Turn the knurled screw until compressed air audibly escapes. If thesafety valve does not function properly, it should be cleaned. If it still doesnot function, it must be replaced.

NOTE: A defective safety valve may be replaced only with an original sparepart. Only the manufacturer may perform repairs to the safety valve!

Fig. 5-18

Cleaning

Pollution that has penetrated fitting surfaces and conical nipples can beremoved by unscrewing the entire top piece – without changing theminimum operating pressure. Use a sickle wrench to unscrew.

Fig. 5-19

Maintenance5-20


Pressure SensorAvailable only with options Pressure display and Pressure control.

WARNING: System or material pressurized. Relieve pressure. Failure toobserve may result in serious burns.

Cleaning Separating MembraneWARNING: Hot! Risk of burns. Wear appropriate protectiveclothing/equipment.

CAUTION: Clean the separating membrane (arrow, Fig. 5-20) withparticular care. Never use hard tools.

Whenever possible, remove material residue only with a cleaning agentrecommended by the material supplier. Thermoplastic substances such ashot melt adhesive may need to be heated with a hot air fan and thencarefully wiped off with a soft cloth.

Fig. 5-20

Screwing in Pressure SensorNOTE: The unit part and the pressure sensor should be at or near roomtemperature before the pressure sensor is screwed in firmly.

1. Apply high temperature grease to the thread (Refer to ProcessingMaterials).

2. Only screw pressure sensor into a very clean hole.

NOTE: Do not tilt or jam when screwing into place.

Max. installation torque permitted: 56 Nm / 500 lbin

CAUTION: If the material hole is to be cleaned with a hard object, thepressure sensor must first be removed; otherwise the separating membranewould be damaged.

Fig. 5-21 Principle drawing

Maintenance 5-21


Filling ValveAvailable only with option Level control with filling connection (box 16, codeB and P).

Fig. 5-22 Deaeration hole

Replacing Control Module

Nordson recommends keeping a supply of control modules on hand to pre-vent disruptions in production.

NOTE: Replace only when control module is warm and material is soft(approx. 70 �C / 158 �F, depending on material).

WARNING: System or material pressurized. Relieve pressure. Failure toobserve may result in serious burns.

1. Disconnect air supply and electrical connection.

2. Release screws M5 and extract control module from the warm fillingvalve.

3. Put new control module in place and tighten screws crosswise.

4. Re-connect air supply and electrical connection.

NOTE: Observe voltage shown on solenoid valve ID plate.

Maintenance5-22


Maintenance Record Form

Unit part Activity Date Name Date Name

Visual inspection ofltmelter

External cleaning ofltmelter

Tank

Safety valve

Fan and air filter

Heat exchanger

Gear pump

Motor / gear box

Maintenance 5-23


Unit part Activity Date Name Date Name

Pressure control valve

Filter cartridge

Safety valve plate

Tank isolation valve

Pneumatic safety valve

Pressure sensor

Filling valve (option)

Level and overflowt ti l tprotection evaluators

Maintenance5-24


Section 5 Maintenance - Nordsonemanuals.nordson.com/adhesives/english_manuals/main_abc.pdf · 2004...

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Transcript of Section 5 Maintenance - Nordsonemanuals.nordson.com/adhesives/english_manuals/main_abc.pdf · 2004...